Recyclable tufted carpet product

ABSTRACT

Recyclable tufted carpet products and methods of preparing the same are provided. In particular, the recyclable tufted carpet product includes a primary backing having an air permeability greater than 100 l/m 2 /sec at 200 Pa/20 cm 2 , the primary backing comprising a polyester nonwoven; a plurality of yarns tufted through the primary backing such that a pile is provided at a first surface of the primary backing and a plurality of yarn loops are provided at a second surface of the primary backing; and an adhesive that anchors the plurality of yarn loops to the second surface of the primary backing.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of priority of U.S. patentapplication Ser. No. 16/577,783 filed on Sep. 20, 2019, and EuropeanPatent Application No. 19204778.5 filed on Oct. 23, 2019, the entirecontents of which are hereby incorporated by reference in their entiretyfor all purposes.

FIELD

The presently-disclosed invention relates generally to recyclable tuftedcarpet products and methods of making the same, and more particularly torecyclable tufted carpet products having a primary backing with aminimum air permeability that provides improved tear resistance, tensilestrength, and tuft bind strength and methods of making the same.

BACKGROUND

Conventional tufted fabrics such as carpets and rugs are made up ofvarious components and different types of material. Various componentsinclude a primary backing, secondary backing, latex adhesives and tuftmaterial. It is common practice to produce fabrics such as carpetsincorporating a primary backing of natural or synthetic plasticmaterials such as polypropylene in a woven fabric form. For example,broadloom carpets are normally produced by having a primary backing ofwoven slit film polypropylene into which there is inserted a pluralityof tufts by a tufting machine. Tufts may be made from natural orsynthetic fibers including wool, polyamides, polyester (e.g.,polytrimethylene terephthalate), polypropylene, and acrylics. Thesetufts, forming the pile of the carpet, extend through the primarybacking from one face to the other in the form of loops such that longloops on one side form the pile of the carpet and the short loops arelocated on the opposed side of the backing. Cut pile carpet is achievedby cutting the long loops on the face of the carpet. An adhesivecoating, e.g., of latex, is then applied as a primary anchor coat to theside of the primary backing opposite the pile side in order to lock thetufts in the primary backing.

The necessity for an anchor coat such as latex results in a relativelyheavy fabric which in some cases lacks optimum flexibility. The latexalso has a water component that must be driven off during manufacture,which requires ovens that consume high amounts of energy. In addition,carpets formed with a latex backing require formation on a tenter frameto prevent the latex from shrinking during drying. In addition to themanufacturing inconvenience of using a tenter frame, the residual stresscaused by the tenting process requires carpets made with a latex backingto be stretched when installed, which in turn requires additional laborand components such as tack strips to hold the stretched carpet inplace.

Also, it is well-known in the industry that most carpet is disposed ofin a landfill, taking up considerable space thereof. To eliminate thedisposal of carpets in landfills requires the construction of carpets ofrecyclable materials in all parts of the carpet. One approach torecyclable carpet would be to dissemble the carpet and recycle theindividual materials. Due to the plurality of materials and the latexadhesive used in this approach to date, this has not been feasible.

Moreover, it is perceived that polyester nonwovens are unfit to serve asa primary backing due to poor tear resistance, tensile strength, andtuft bind strength during and after tufting.

Accordingly, there still exists a need for recyclable tufted carpetproducts made of recyclable materials without a latex adhesive andhaving a polyester non-woven primary backing designed to eliminate thedisadvantages noted above. Such materials are recyclable because thelayers do not require mechanical or chemical separation to remove latexand because the entire tufted carpet product can be melted down due tothe use of the same or similar materials.

BRIEF SUMMARY

One or more embodiments of the invention may address one or more of theaforementioned problems. Certain embodiments according to the inventionprovide fully recyclable tufted carpet products having polyesternonwoven primary backings with a minimum air permeability that providesimproved tear resistance, tensile strength, and tuft bind strength afterthe fabric is tufted. In particular, according to a first aspect of theinvention, a tufted carpet product is provided, the carper beingrecyclable. The tufted carpet product comprises a primary backing havingan air permeability greater than 100 l/m²/sec at 200 Pa/20 cm², theprimary backing comprising a polymer (e.g., polyester) nonwoven; aplurality of polymer yarns tufted through the primary backing such thata pile is provided at a first surface of the primary backing and aplurality of yarn loops are provided at a second surface of the primarybacking; and an adhesive that anchors the plurality of yarn loops to thesecond surface of the primary backing.

According to some embodiments, the polymer of the nonwoven may besimilar or identical to the polymer of the yarn. The polymer of thenonwoven and the polymer of the yarn may both be a polyester.

According to some embodiments, the primary backing may comprise an airpermeability from about 1000 to about 40001/m²/sec.

According to some embodiments, the primary backing may comprise athickness greater than 0.35 mm at 0.5 Pa/25 cm². Unless otherwisementioned, thicknesses are measured under a pressure applied, thepressure being 0.5 Pa over 25 cm².

According to some embodiments, the adhesive may comprise a polyester hotmelt adhesive.

According to some embodiments, the adhesive may comprise a polyesternonwoven secondary backing.

According to some embodiments, the tufted yarn may comprise or evenconsist of polyester, such as virgin polyester, e.g. virgin PET, orrecycled polyester, such as recycled PET, or any combination of such.

In a second aspect of the invention, a method of preparing a tuftedcarpet product is provided, the carpet being recyclable. The methodcomprises providing a primary backing having an air permeability greaterthan 100 l/m²/sec at 200 Pa/20 cm², the primary backing comprising apolymer (e.g., polyester) nonwoven; tufting a polymer (e.g., polyester)yarn through the primary backing such that a pile is provided at a firstsurface of the primary backing and a plurality of yarn loops areprovided at a second surface of the primary backing; and anchoring theplurality of yarn loops to the second surface of the primary backing.

According to some embodiments, the polymer of the nonwoven may b similaror identical to the polymer of the yarn. The polymer of the nonwoven andthe polymer of the yarn may both be a polyester.

According to some embodiments, the primary backing may comprise or havean air permeability from about 1000 to about 4000 l/m²/sec at 200 Pa/20cm². According to some embodiments, prior to the tufting step, theprimary backing may comprise or have a thickness greater than 0.35 mm at0.5 Pa/25 cm².

According to some embodiments, the primary backing may comprisepolyethylene terephthalate (PET) filaments and copolymer of polyethyleneterephthalate (coPET) filaments. The primary backing may comprise 80-100wt % PET and 0-20 wt % coPET. This w % is based upon the total weight ofthe primary backing.

According to some embodiments, the primary backing may be at least oneof hydroentangled, needled, calendered, and/or through air bonded priorto tufting.

According to some embodiments, the recyclable tufted carpet product maybe free of latex.

According to some embodiments, anchoring the plurality of yarn loops tothe second surface of the primary backing may make use of an adhesive byapplying said adhesive to the second surface of the primary backing.Anchoring the plurality of yarn loops to the second surface of theprimary backing may comprise applying a polyester hot melt adhesive tothe plurality of yarn loops and the second surface of the primarybacking.

According to some embodiments, anchoring the plurality of yarn loops tothe second surface of the primary backing my comprise applying anonwoven secondary backing to the plurality of yarn loops and the secondsurface of the primary backing. The nonwoven secondary backing maycomprise PET and coPET. The non-woven secondary backing may comprisegreater than 50 wt % coPET with the remainder being PET.

The independent and dependent claims set out particular and preferredfeatures of the invention. Features from the dependent claims may becombined with features of the independent or other dependent claims,and/or with features set out in the description above and/or hereinafteras appropriate. E.g. features of the first aspect of the invention maybe combined with features of the second aspect of the invention and viceversa.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

Having thus described the invention in general terms, reference will nowbe made to the accompanying drawings, which are not necessarily drawn toscale, and wherein:

FIG. 1 illustrates a tufted primary backing in accordance with certainembodiments of the invention;

FIG. 2 illustrates application of an adhesive to a tufted primarybacking in accordance with certain embodiments of the invention;

FIG. 3 illustrates a tufted carpet product in accordance with certainembodiments of the invention;

FIGS. 4 and 5 illustrate simplified schematic cross-sections of anon-woven primary backing in accordance with certain embodiments of theinvention;

FIGS. 6 and 7 illustrate simplified schematic cross-section of anon-woven secondary backing in accordance with certain embodiments ofthe invention;

FIG. 8 illustrates the step of providing a primary backing in accordancewith certain embodiments of the invention; and

FIGS. 9 and 10 are block diagrams of a method of preparing a recyclabletufted carpet product in accordance with certain embodiments of theinvention.

DETAILED DESCRIPTION

The invention now will be described more fully hereinafter withreference to the accompanying drawings, in which some, but not allembodiments of the inventions are shown. Indeed, this invention may beembodied in many different forms and should not be construed as limitedto the embodiments set forth herein; rather, these embodiments areprovided so that this disclosure will satisfy applicable legalrequirements. Like numbers refer to like elements throughout. As used inthe specification, and in the appended claims, the singular forms “a”,“an”, “the”, include plural referents unless the context clearlydictates otherwise.

The invention includes, according to certain embodiments, tufted carpetproducts that are fully recyclable and utilize a polyester nonwovenprimary backing having a minimum air permeability that provides improvedtear resistance, tensile strength, and tuft bind strength after thefabric is tufted. In particular, embodiments of the invention aredirected to recyclable tufted carpet products having a polymer (e.g.,polyester) nonwoven primary backing having an air permeability greaterthan 100 l/m²/sec at 200 Pa/20 cm², a plurality of polymer yarns tuftedthrough the primary backing such that a pile is provided at a firstsurface of the primary backing and a plurality of yarn loops areprovided at a second surface of the primary backing, and an adhesivethat anchors the plurality of yarn loops to the second surface of theprimary backing. As such, the recyclable tufted carpet product includesa primary backing with an air permeability that advantageously providesimproved tear strength, tensile strength, and tuft bind strength. Inthis regard, layers of the tufted carpet product all comprise apolyester and are joined together without a latex adhesive. Thesefeatures make the tufted carpet product fully recyclable.

I. Definitions

The terms “polymer” or “polymeric”, as used interchangeably herein, maycomprise homopolymers, copolymers, such as, for example, block, graft,random, and alternating copolymers, terpolymers, etc., and blends andmodifications thereof. Furthermore, unless otherwise specificallylimited, the term “polymer” or “polymeric” shall include all possiblestructural isomers; stereoisomers including, without limitation,geometric isomers, optical isomers or enantionmers; and/or any chiralmolecular configuration of such polymer or polymeric material. Theseconfigurations include, but are not limited to, isotactic, syndiotactic,and atactic configurations of such polymer or polymeric material. Theterm “polymer” or “polymeric” shall also include polymers made fromvarious catalyst systems including, without limitation, theZiegler-Natta catalyst system and the metallocene/single-site catalystsystem.

The term “air permeability”, as used herein, may refer to the rate ofairflow passing perpendicularly through a known area under a prescribedair pressure differential between the two surfaces of a material. Inother words, permeability refers to how easily air, or water, flowsthrough a material having a controlled size alignment of pores. Airpermeability differs from porosity in that porosity is the amount ofempty space in a solid and is indicative of how much water a materialcan hold. For the purposes of this disclosure, air permeability may bemeasured according to ISO 9073-15 and/or ASTM D737-96.

The terms “tear strength” and “tear resistance”, as used herein, mayrefer to a measure of how well a material can withstand the effects oftearing. For example, tear strength or tear resistance may refer to afabric's resistance to tearing once cut. For the purposes of thisdisclosure, tear strength/tear resistance may be measured according toISO 9073-4 and/or NWSP 100.R1.

The term “nonwoven”, as used herein, may comprise a web having astructure of individual fibers, filaments, and/or threads that areinterlaid but not in an identifiable repeating manner as in a knitted orwoven fabric. Nonwoven fabrics or webs, according to certain embodimentsof the invention, may be formed by any process conventionally known inthe art such as, for example, meltblowing processes, spunbondingprocesses, hydroentangling, air-laid, and bonded carded web processes.

The term “meltspun”, as used herein, may comprise fibers which areformed by extruding molten thermoplastic material as filaments from aplurality of fine, usually circular or trilobal, die capillaries of aspinneret and solidifying the extruded filaments by cooling them as theyemerge from the die capillaries.

The term “spunbond”, as used herein, may comprise fibers which areformed by extruding molten thermoplastic material as filaments from aplurality of fine, usually circular or trilobal, capillaries of aspinneret with the diameter of the extruded filaments then being rapidlyreduced. According to an embodiment of the invention, spunbond fibersare generally not tacky when they are deposited onto a collectingsurface and may be generally continuous.

The term “meltblown”, as used herein, may comprise fibers formed byextruding a molten thermoplastic material through a plurality of finedie capillaries as molten threads or filaments into converging highvelocity, usually hot, gas (e.g. air) streams which attenuate thefilaments of molten thermoplastic material to reduce their diameter,which may be to microfiber diameter, according to certain embodiments ofthe invention. According to an embodiment of the invention, the diecapillaries may be circular. Thereafter, the meltblown fibers arecarried by the high velocity gas stream and are deposited on acollecting surface to form a web of randomly disbursed meltblown fibers.Meltblown fibers are microfibers which may be continuous ordiscontinuous and are generally tacky when deposited onto a collectingsurface.

The term “bicomponent fibers”, as used herein, may comprise fibersformed from at least two different polymers extruded from separateextruders but spun together to form one fiber. Bicomponent fibers arealso sometimes referred to as conjugate fibers or multicomponent fibers.The polymers are arranged in a substantially constant position indistinct zones across the cross-section of the bicomponent fibers andextend continuously along the length of the bicomponent fibers. Theconfiguration of such a bicomponent fiber may be, for example, asheath/core arrangement wherein one polymer is surrounded by another, ormay be a side-by-side arrangement, a homo-homo arrangement, a piearrangement, or an “islands-in-the-sea” arrangement, each as is known inthe art of multicomponent, including bicomponent, fibers. The“bicomponent fibers” may be thermoplastic fibers that comprise a corefiber made from one polymer that is encased within a thermoplasticsheath made from a different polymer or have a side-by-side arrangementof different thermoplastic fibers. The first polymer often melts at adifferent, typically lower, temperature than the second polymer. In thesheath/core arrangement, these bicomponent fibers provide thermalbonding due to melting of the sheath polymer, while retaining thedesirable strength characteristics of the core polymer.

II. Recyclable Tufted Carpet Product

Certain embodiments according to the invention provide tufted carpetproducts that are fully recyclable and utilize a polyester nonwovenprimary backing having a minimum air permeability that provides improvedtear resistance, tensile strength, and tuft bind strength after thefabric is tufted. For example, certain embodiments of the inventionprovide tufted carpet products having a tear strength of greater than100 N in MD and CD, tensile strength of greater than 220 N/50 mm in MDand CD, and tuft bind strength of greater than 6 lbs loop and greaterthan 3 lbs cut pile. In particular, embodiments of the invention aredirected to recyclable tufted carpet products having a polymer nonwovenprimary backing having an air permeability greater than 100 l/m²/sec at200 Pa/20 cm², a plurality of polymer yarns tufted through the primarybacking such that a pile is provided at a first surface of the primarybacking and a plurality of yarn loops are provided at a second surfaceof the primary backing, and an adhesive that anchors the plurality ofyarn loops to the second surface of the primary backing. As such, therecyclable tufted carpet product includes a primary backing with anadvantageous air permeability that provides improved tear strength,tensile strength, and tuft bind strength. In this regard, layers of thetufted carpet product all comprise a polyester and are joined togetherwithout a latex adhesive. These features make the tufted carpet productfully recyclable.

Turning now to FIG. 1, a tufted primary backing 1 is illustrated inaccordance with certain embodiments of the invention. As shown in FIG.1, the primary backing 1 includes a plurality of yarns 12 tufted throughthe primary backing 1 such that a plurality of loops 14 of yarn 12 areprovided both at a first surface 10 of the primary backing 1 and asecond surface 17 of the primary backing 1. As indicated by line 13, theplurality of loops 14 of yarn 12 may be cut to create piles 15, shown inFIGS. 2 and 3. In some embodiments, yarns 12 may comprise a polyester.For example, in certain embodiments, yarns 12 may comprise polyethyleneterephthalate (PET).

Primary backing 1 may comprise a polymer nonwoven. Yarns 12 similarlymay comprise a polymer that may be the same as or similar to the polymerof primary backing 1. For instance, primary backing 1 may comprise apolyester nonwoven. For example, in some embodiments, primary backing 1may comprise PET and a copolymer of PET (coPET). Indeed, in someembodiments and as shown in FIG. 4, for instance, primary backing 1 maycomprise a plurality of PET filaments 32 and a plurality of coPETfilaments 34 randomly interspersed among the plurality of PET filaments32.

This random interspersion can be achieved via, for example, aspunbonding or meltblowing process. In such embodiments, for example,PET filaments 32 may have a larger filament titer than coPET filaments34. For instance, in some embodiments PET filaments 32 may be about 4-12denier, while coPET filaments 34 may be about 2-5 denier. In furtherembodiments, for example, PET filaments 32 may be about 6 denier, whilecoPET filaments 34 may be about 2-3 denier. Although FIG. 4 illustratesthe coPET filaments 34 as being randomly interspersed with the PETfilaments 32, the coPET filaments 34 may also be distributed evenlyand/or according to a pattern as understood by one of ordinary skill inthe art. In addition, FIG. 4 (and FIGS. 5-7 as discussed below) is aschematic view for ease of illustration of the different filament types,and in practice the filaments would be generally more densely-packed andrandomly-oriented. Further, after the coPET filaments are at leastpartially melted, a substantial portion of primary backing 1 may remainin the form of the PET filaments 32.

Moreover, although primary backing 1 has been described thus far ashaving separate PET filaments and coPET filaments, primary backing 1may, in other embodiments, comprise all or a portion of bicomponentfibers having a core formed at least in part by PET and a low meltsheath formed at least in part by coPET. FIG. 5, for example,illustrates a cross-section of primary backing 1 in accordance withcertain embodiments of the invention. As shown in FIG. 5, coPET may bedisposed at or along, at least in part, the sheath 44 (i.e. the outsidesurface) of the bicomponent fiber 40, and PET may be disposed in thecore 42 (i.e. inner portion) of the bicomponent fiber 40. Duringheating, coPET sheath 44 may melt while the PET in the coresubstantially maintains its fiber shape and structural integrity. As aperson of ordinary skill in the art would comprehend having the benefitof this disclosure, both the amount of coPET in the fiber of primarybacking 1 and the extent of energy (e.g., heat) supplied to primarybacking 1 will be determinative of the extent of melting in primarybacking 1 relative to other layers heated in the same manner but havingperhaps a different amount of coPET in the fiber and/or the extent ofenergy (e.g., heat) supplied. In addition, although all of the fibersillustrated in FIG. 5 are shown as having a bicomponent form,embodiments of the invention also include primary backings where only aportion of the fibers are bicomponent, and the remaining fibers are ofanother type, such as coPET filaments 34 and/or PET filaments 32.Regardless of whether individual filaments or bicomponent fibers areused, in some embodiments, for example, primary backing 1 may includeapproximately 0-20 wt % coPET and 80-100 wt % PET. In furtherembodiments, for instance, primary backing 1 may include approximately15-20 wt % coPET and 80-85 wt % PET.

As noted above, primary backing 1 may be a polyester non-woven.According to certain embodiments of the invention, primary backing 1 maycomprise a spunbond, meltblown, or meltspun fabric. In furtherembodiments, the primary backing 1 may comprise multiple layers havingany combination of spunbond, meltblown, and meltspun fabric bondedtogether as understood by a person of ordinary skill in the art. Incertain embodiments, for example, primary backing 1 may comprise aweight of about 2.4-4.4 oz/yd². In further embodiments, for instance,primary backing 1 may comprise a weight of about 3.7 oz/yd².

Polyester nonwovens have, to date, been unable to serve as primarybacking due to poor tear resistance, tensile strength, and tuft bindstrength. Primary backing 1, however, has a minimum air permeabilitythat provides improved tear resistance, tensile strength, and tuft bindstrength that allows it to operate as a strong primary backing. Indeed,according to certain embodiments, primary backing 1 has an airpermeability after the fabric is formed but before it is tufted, asmeasured according to ISO 9073-15 and/or ASTM D737-96, greater than 100l/m²/sec at 200 Pa/20 cm². In further embodiments, for instance, primarybacking 1 has an air permeability greater than 1000 l/m²/sec at 200Pa/20 cm². In some embodiments, for example, primary backing 1 has anair permeability from about 1000 to about 40001/m²/sec at 200 Pa/20 cm².In this way, and without being bound by theory, a primary backing withsuch air permeability may improve tear resistance, tensile strength, andtuft bind strength, as air permeability is indicative of fiber mobility.Indeed, more mobile fibers during tufting means that the fibers can bemore easily moved out of the way by the tufting needles rather thanbroken by the needles. This in turn means that there are fewer sites fortear propagation and/or more sites where overlapping filaments can formbonded nodes with each other, which in turn improves tear strength. Infurther embodiments, for instance, lubricants may be used to furtherimprove fiber mobility.

Moreover, according to certain embodiments, primary backing 1 may have athickness, as measured according to ISO 9073-2 and/or ASTM D5729-97,greater than 0.35 mm at 0.5 Pa/25 cm². For example, in some embodiments,primary backing 1 may have a thickness from about 0.5 to about 1.5 mm at0.5 Pa/25 cm². Moreover, in certain embodiments, for instance, primarybacking 1 may have a basis weight, as measured according to ISO 9073-1and/or ASTM D6242-98, of about 80-140 gsm. In further embodiments, forexample, primary backing 1 may have a basis weight of 100-120 gsm. Suchthickness and basis weight may also improve tear resistance, tensilestrength, and tuft bind strength. However, while going beyond thisthickness and basis weight may further improve tear resistance, tensilestrength, and tuft bind strength, the primary backing may becomeuneconomical as too much raw material is required to make a saleableproduct.

Tear resistance, tensile strength, and tuft bind strength may be furtherimproved by processing primary backing 1 prior to tufting. For example,in some embodiments, primary backing 1 may be hydroentangled or needledprior to tufting. In such embodiments, for example, primary backing 1may be hydroentangled or needled in two directions, once from each sideof the fabric. In other embodiments, for instance, primary backing 1 maybe calendered prior to tufting to at least partially melt the coPET, asshown, for example, FIG. 8, which is described in more detail below.Such calendering may occur with a calender gap or opening of 0.1 mm. Infurther embodiments, for example, primary backing 1 may be subjected tothrough air bonding, i.e. by sucking and/or blowing hot air (e.g., abovethe coPET melting point) through the primary backing to at leastpartially melt the coPET prior to tufting. Regardless of the exactprocessing steps used, primary backing 1 provides most, if not all, ofthe tear strength to the final recyclable tufted carpet product.

Additionally, recyclable tufted carpet product 16 may include anadhesive 11 that anchors the plurality of loops 14 of yarn 12 to thesecond surface 17 of the primary backing 1. For example, FIG. 2illustrates the application of adhesive 11 to tufted primary backing 1to form recyclable tufted carpet product 16, as illustrated in FIG. 3.In applying adhesive 11, however, the loops 14 of yarn 12 do not need tobe further fused to the primary backing 1 such as with relative movementbetween a heated roll or knife and the loops of the tufts as is known inthe prior art. In some embodiments, for example, adhesive 11 may be aglue. For instance, in further embodiments, adhesive 11 may be a liquidglue comprising, for example, coPET. Indeed, in some embodiments,adhesive 11 may be a hot melt adhesive, e.g., molten coPET.

In other embodiments, however, such as those illustrated in FIGS. 6 and7, adhesive 11 may be a secondary backing. In such embodiments, forexample, adhesive 11 (i.e. the secondary backing) may comprise PET and acopolymer of PET (coPET). Indeed, in some embodiments and as shown inFIG. 6, for instance, adhesive 11 (i.e. the secondary backing) maycomprise a plurality of PET filaments 52 and a plurality of coPETfilaments 54 randomly interspersed among the plurality of PET filaments52. This random interspersion can be achieved via, for example, aspunbonding or meltblowing process. Although FIG. 6 illustrates thecoPET filaments 54 as being randomly interspersed with the PET filaments52, the coPET filaments 54 may also be distributed evenly and/oraccording to a pattern as understood by one of ordinary skill in theart. In this regard, after the coPET filaments are at least partiallymelted, a substantial portion of adhesive 11 (i.e. the secondarybacking) may remain in the form of the PET filaments 52.

Moreover, although adhesive 11 (i.e. the secondary backing) has beendescribed thus far as having separate PET filaments and coPET filaments,adhesive 11 (i.e. the secondary backing) may, in other embodiments,comprise all or a portion of bicomponent fibers having a core formed atleast in part by PET and a low melt sheath formed at least in part bycoPET. FIG. 7, for example, illustrates a schematic view of adhesive 11(i.e. the secondary backing) in accordance with certain embodiments ofthe invention. As shown in FIG. 7, the coPET may be disposed at oralong, at least in part, the sheath 64 (i.e. the outside surface) of thebicomponent fiber 60, and PET may be disposed in the core 62 (i.e. innerportion) of the bicomponent fiber 60. During heating, coPET sheath 64may melt while the PET in the core substantially maintains its fibershape and structural integrity. As a person of ordinary skill in the artwould comprehend having the benefit of this disclosure, both the amountof coPET in the fiber of adhesive 11 (i.e. the secondary backing) andthe extent of energy (e.g., heat) supplied to adhesive 11 (i.e. thesecondary backing) will be determinative of the extent of melting inadhesive 11 (i.e. the secondary backing) relative to other layers heatedin the same manner but having perhaps a different amount of coPET in thefiber and/or the extent of energy (e.g., heat) supplied. In addition,although all of the fibers illustrated in FIG. 7 are shown as having abicomponent form, embodiments of the invention also include secondarybackings where only a portion of the fibers are bicomponent, and theremaining fibers are of another type, such as coPET filaments 54 and/orPET filaments 52. Regardless of whether individual filaments orbicomponent fibers are used, in some embodiments, for example, adhesive11 (i.e. the secondary backing) may include greater than 50 wt % coPET,with the remainder being PET. In further embodiments, for instance,adhesive 11 (i.e. the secondary backing) may include approximately 80 wt% coPET and 20 wt % PET. Moreover, in some embodiments, the secondarybacking may comprise a basis weight, as measured according to ISO 9073-1and/or ASTM D6242-98, of about 100-150 gsm. For example, in certainembodiments, the secondary backing may comprise a basis weight ofapproximately 135 gsm. As above with the primary backing, going beyondthis thickness and basis weight may further improve tear resistance,tensile strength, and tuft bind strength, but the adhesive (secondarybacking) may become uneconomical as too much raw material is required tomake a saleable product.

In this regard, the resulting tufted carpet product is free of latex andis fully recyclable. Moreover, the recyclable tufted carpet productutilizes a polyester nonwoven primary backing having a minimum airpermeability that provides improved tear resistance, tensile strength,and tuft bind strength.

III. Method of Preparing a Recyclable Tufted Carpet Product

In another aspect, certain embodiments according to the inventionprovide methods of preparing a recyclable tufted carpet product. Inaccordance with certain embodiments, the method comprises providing aprimary backing having an air permeability greater than 100 l/m²/sec at200 Pa/20 cm², the primary backing comprising a polymer nonwoven;tufting a polymer yarn through the primary backing such that a pile isprovided at a first surface of the primary backing and a plurality ofyarn loops are provided at a second surface of the primary backing; andanchoring the plurality of yarn loops to the second surface of theprimary backing.

FIG. 9, for example, is a block diagram of a method 90 of preparing arecyclable tufted carpet product in accordance with certain embodimentsof the invention. As shown in FIG. 9, the method 90 includes thefollowing steps:

Step 91: Providing a primary backing having an air permeability greaterthan 100 l/m²/sec at 200 Pa/20 cm², the primary backing comprising apolymer non-woven;

Step 92: Tufting a polymer yarn through the primary backing such that apile is provided at a first surface of the primary backing and aplurality of yarn loops are provided at a second surface of the primarybacking; and

Step 93: Anchoring the plurality of yarn loops to the second surface ofthe primary backing.

Step 91 is shown in more detail in FIG. 8. As shown in FIG. 8, providinga primary backing 1 is shown in step S1. Primary backing 1 is anon-woven layer comprising continuous filaments 2, provided byspunbonding technology. In this case the filaments 2 are bicomponentfilaments. Two extruders 3, each for one of the components of thefilaments, are fed with respective polymer chips through respectiveinlets 4. Filaments 2 are formed by extrusion and drawing through aspinning die 5 and aspirator (not shown). The filaments 2 are laid on amoving screen or belt 6 to form a web. The web may optionally besubjected to a bonding step S2 e.g. by calender bonding. In calenderbonding the web of loose filaments 2 is passed through the nip 7 of aset of rollers 8, of which preferably at least one is heated. One ormore of the rollers 8 may optionally be patterned.

As discussed previously herein, however, primary backing 1 may beprocessed prior to tufting by one or more of calendering,hydroentangling, needling, or through air bonding. FIG. 10 is a blockdiagram of a method 100 of preparing a recyclable tufted carpet productin accordance with certain embodiments of the invention, includingoptions for the processing steps and options for the anchoring step. Thebelow steps are merely options and, as such, their listed order is notlimiting and several listed steps are interchangeable. For example,needling and hydroentangling are interchangeable, as are calendering andthrough air bonding. As shown in FIG. 10, the method 100 includes thefollowing steps:

Step 101: Needling the primary backing; and/or

Step 102: Hydroentangling the primary backing; and/or

Step 103: Calendering the primary backing; and/or

Step 104: Through air bonding the primary backing; followed by

Step 105: Tufting a polymer yarn through the primary backing such that apile is provided at a first surface of the primary backing and aplurality of yarn loops are provided at a second surface of the primarybacking; and

Step 106: Applying a polyester hot melt adhesive to the plurality ofyarn loops and the second surface of the primary backing; and/or

Step 107: Applying a nonwoven secondary backing to the plurality of yarnloops and the second surface of the primary backing.

According to certain embodiments, for example, the recyclable tuftedcarpet product may be heated following Step 106 and/or Step 107 to atleast partially melt the coPET in the secondary backing.

Moreover, according to certain embodiments of the invention, forexample, tufting the plurality of yarns into the primary backing maycomprise tufting with a tufting machine as understood by a person havingordinary skill in the art.

In this regard, the method provides a tufted carpet product that isfully recyclable and that utilizes a polyester nonwoven primary backinghaving a minimum air permeability that provides improved tearresistance, tensile strength, and tuft bind strength.

EXEMPLARY EMBODIMENTS

Certain embodiments according to the invention provide fully recyclabletufted carpet products having polyester nonwoven primary backings withimproved tear resistance and air permeability. In particular, accordingto a first aspect of the invention, a recyclable tufted carpet productis provided. The recyclable tufted carpet product comprises a primarybacking having an air permeability greater than 100 l/m²/sec at 200Pa/20 cm², the primary backing comprising a polymer nonwoven; aplurality of polymer yarns tufted through the primary backing such thata pile is provided at a first surface of the primary backing and aplurality of yarn loops are provided at a second surface of the primarybacking; and an adhesive that anchors the plurality of yarn loops to thesecond surface of the primary backing.

According to certain embodiments, for example, the polymer of thenonwoven is similar or identical to the polymer of the yarn. In furtherembodiments, for instance, the polymer of the nonwoven and the polymerof the yarn are both a polyester.

According to certain embodiments, for example, the primary backingcomprises an air permeability from about 1000 to about 4000 l/m²/sec. Infurther embodiments, for instance, the primary backing comprises athickness greater than 0.35 mm at 0.5 Pa/25 cm².

According to certain embodiments, for example, the adhesive comprises apolyester hot melt adhesive. In other embodiments, for instance, theadhesive comprises a polyester nonwoven secondary backing.

In a second aspect of the invention, a method of preparing a recyclabletufted carpet product is provided. The method of preparing a recyclabletufted carpet product comprises providing a primary backing having anair permeability greater than 1000 l/m²/sec at 200 Pa/20 cm², theprimary backing comprising a polymer non-woven; tufting a polymer yarnthrough the primary backing such that a pile is provided at a firstsurface of the primary backing and a plurality of yarn loops areprovided at a second surface of the primary backing; and anchoring theplurality of yarn loops to the second surface of the primary backing.

According to certain embodiments, for example, the polymer of thenonwoven is similar or identical to the polymer of the yarn. In furtherembodiments, for instance, the polymer of the nonwoven and the polymerof the yarn are both a polyester.

According to certain embodiments, for example, the primary backingcomprises an air permeability from about 1000 to about 4000 l/m²/sec. Insome embodiments, for instance, prior to the tufting step the primarybacking comprises a thickness greater than 0.35 mm at 0.5 Pa/25 cm². Infurther embodiments, for example, the primary backing comprisespolyethylene terephthalate (PET) filaments and copolymer of polyethyleneterephthalate (coPET) filaments. In certain embodiments, for instance,the primary backing comprises 80-85 wt % PET and 15-20 wt % coPET.

According to certain embodiments, for instance, the primary backing isat least one of hydroentangled, needled, calendered, and/or through airbonded prior to tufting.

According to certain embodiments, for example, the recyclable tuftedcarpet product is free of latex.

According to certain embodiments, for example, anchoring the pluralityof yarn loops to the second surface of the primary backing comprisesapplying a polyester hot melt adhesive to the plurality of yarn loopsand the second surface of the primary backing. In some embodiments, forinstance, the polyester hot melt adhesive comprises coPET. In otherembodiments, for example, anchoring the plurality of yarn loops to thesecond surface of the primary backing comprises applying a nonwovensecondary backing to the plurality of yarn loops and the second surfaceof the primary backing. In certain embodiments, for instance, thenonwoven secondary backing comprises PET and coPET. In furtherembodiments, for example, the secondary backing comprises greater than50 wt % coPET with the remainder being PET.

Modifications of the invention set forth herein will come to mind to oneskilled in the art to which the invention pertains having the benefit ofthe teachings presented in the foregoing descriptions and the associateddrawings. Therefore, it is to be understood that the invention is not tobe limited to the specific embodiments disclosed and that modificationsand other embodiments are intended to be included within the scope ofthe appended claims. Although specific terms are employed herein, theyare used in a generic and descriptive sense only and not for purposes oflimitation.

1. A method of preparing a recyclable tufted carpet product, the methodcomprising: providing a primary backing having an air permeabilitygreater than 100 l/m²/sec at 200 Pa/20 cm², the primary backingcomprising a polymer non-woven; tufting a polymer yarn through theprimary backing such that a pile is provided at a first surface of theprimary backing and a plurality of yarn loops are provided at a secondsurface of the primary backing; and anchoring the plurality of yarnloops to the second surface of the primary backing.
 2. The methodaccording to claim 1, wherein the polymer of the nonwoven is similar oridentical to the polymer of the yarn.
 3. The method according to claim1, wherein the polymer of the nonwoven and the polymer of the yarn areboth a polyester.
 4. The method according to claim 1, wherein theprimary backing comprises an air permeability from about 1000 to about4000.
 5. The method according to claim 1, wherein prior to the tuftingstep the primary backing comprises a thickness greater than 0.35 mm at0.5 Pa/25 cm².
 6. The method according to claim 1, wherein the primarybacking comprises polyethylene terephthalate (PET) filaments andcopolymer of polyethylene terephthalate (coPET) filaments.
 7. The methodaccording to claim 6, wherein the primary backing comprises 80-100 wt %PET and 0-20 wt % coPET.
 8. The method according to claim 1, wherein theprimary backing is at least one of hydroentangled, needled, calendered,and/or through air bonded prior to tufting.
 9. The method according toclaim 1, wherein the recyclable tufted carpet product is free of latex.10. The method according to claim 1, wherein anchoring the plurality ofyarn loops to the second surface of the primary backing comprisesapplying a polyester hot melt adhesive to the plurality of yarn loopsand the second surface of the primary backing.
 11. The method accordingto claim 1, wherein anchoring the plurality of yarn loops to the secondsurface of the primary backing comprises applying a nonwoven secondarybacking to the plurality of yarn loops and the second surface of theprimary backing.
 12. The method according to claim 11, wherein thenonwoven secondary backing comprises PET and coPET.
 13. The methodaccording to claim 12, wherein the nonwoven secondary backing comprisesgreater than 50 wt % coPET with the remainder being PET.
 14. Arecyclable tufted carpet product comprising: a primary backing having anair permeability greater than 100 l/m²/sec at 200 Pa/20 cm², the primarybacking comprising a polymer non-woven; a plurality of polymer yarnstufted through the primary backing such that a pile is provided at afirst surface of the primary backing and a plurality of yarn loops areprovided at a second surface of the primary backing; and an adhesivethat anchors the plurality of yarn loops to the second surface of theprimary backing.
 15. The recyclable tufted carpet product according toclaim 14, wherein the polymer of the nonwoven is similar or identical tothe polymer of the yarn.
 16. The recyclable tufted carpet productaccording to claim 14, wherein the polymer of the nonwoven and thepolymer of the yarn are both a polyester.
 17. The recyclable tuftedcarpet product according to claim 14, wherein the primary backingcomprises an air permeability from about 1000 to about
 4000. 18. Therecyclable tufted carpet product according to claim 14, wherein theprimary backing comprises a thickness greater than 0.35 mm at 0.5 Pa/25cm².
 19. The recyclable tufted carpet product according to claim 14,wherein the adhesive comprises a polyester hot melt adhesive.
 20. Therecyclable tufted carpet product according to claim 14, wherein theadhesive comprises a polyester nonwoven secondary backing.